Portable modular factory structure and method of constructing same

ABSTRACT

A method of converting shipping containers containing factory equipment into a modular portable factory which comprises transporting the shipping containers to the factory site and aligning the containers in a side-by-side relation with their facing walls, to define the walls of the factory and floor of the factory. A roof structure spans over the top of the container to form top closure for the factory and access doors and stairways are provided in the factory. Shipping containers (main storage units) containing building materials are mounted on a foundation with the supply containers placed perpendicular, parallel or angled to the main storage units. The supply containers are movable by a supply track and the product moved by an assembly track, respectively, and turntables at the end of each of these tracks are operatively connected to the tracks to move the supplies or products in a desired direction.  
     The invention also provides a novel portable modular factory which can be assembled on one site and readily disassembled for relocation to another site.

FIELD OF THE INVENTION

[0001] The present invention relates broadly to a method of on-site assembly of a modular structure and to the structure made by this method. In one aspect, the present invention relates to a method of on-site assembly of a factory using multiple shipping containers transported to the site and joined together at the site to form a factory, and which can be disassembled and moved to another site. In a particular aspect, the present invention is directed to a method of using shipping container modules for the construction of an open ended assembly line plant with continuous pass through of supplies externally and laterally of the assembly line, which plant is adapted to be disassembled and transported to another site.

BACKGROUND OF THE INVENTION

[0002] The fabrication and assembly of a structure such as a house or a factory is usually accomplished on-site using conventional equipment, materials of construction and construction procedures. Several problems are common and inherent in conventional construction of houses or other structures. These problems include subcontracting the various disciplines and their coordination, safety, quality control, availability of materials at the time they are needed, weather-related delays, theft and vandalism, all of which can cause delay in completing the construction, frequently adding to the construction cost and resulting in reduction of anticipated profits. For some time modular homes or modular building have received considerable attention due to lower cost, higher quality and energy efficiency, the speed of construction and ease of transportation, and rapid assembly at the site on a pre-installed foundation. As it can be appreciated, however, the transportation of pre-fabricated structures or “prefabs” as they are sometimes called, can be limited to their module size. Thus, as a practical matter, it is inconvenient, impractical and economically disadvantageous to ship large factories or assembly plants from one site to another, often at distant location.

[0003] The aforementioned difficulties have been recognized and, to some extent, addressed by some of the prior art workers in this field. Thus, in an effort to provide a more efficient alternative home construction then what was theretofore available, U.S. Pat. No. 3,605,350 issued to William S. Bowers on Sep. 20, 1971 discloses a relocatable building constructed by the combination of two or more modular building units to form a school structure or other habitable structure.

[0004] U.S. Pat. No. 3,925,679 issued to Berman et al. on Dec. 9, 1975 and its reissue patent, Re No. 30,229 issued on Mar. 11, 1981 disclose the use of multiple shipping containers as structural building modules for transporting equipment to the final installation site and then joining the shipping container modules together to form an integral building structure.

[0005] U.S. Pat. No. 4,599,829 issued to John M. DiMartino, Sr. on Jul. 15, 1986 discloses the use of multiple modular containers to be joined together to form a building such as, e.g., hospital, school and low cost housing.

[0006] U.S. Pat. No. 4,833,841 issued to John C. Ellington, III on May 30, 1989 discloses a form of prefabricated transportable building module with a particular structural design adapted for stand-alone or placed in side-by-side and/or vertically stacked relation with other modules for forming a complete building on a building site with a particular light weight roof structure frame.

[0007] U.S. Pat. No. 4,854,094 issued to Phillip C. Clark on Aug. 8, 1989 describes a method for converting one or more steel shipping containers to a habitable structure. According to this patent, a single steel shipping container may be used as the structure, or several steel shipping containers having removable panels joined together in spaced and/or abutting relationship to form a habitable building with a roof structure, windows and doors.

[0008] U.S. Pat. No. 5,493,817 issued to Jerry Speer on Feb. 27, 1996 describes a transportable mobile workshop and discloses a shipping container having factory equipment mounted at various places within the container for use on oil rig sites.

[0009] U.S. Pat. No. 5,656,491 issued Aug. 12, 1997 to Cassani et al. discloses the construction of a system of mobile modules connected together and integrated with one another for use as biochemical plant. The plant can be disassembled into its individual modules and transported to a different site.

[0010] Notwithstanding the attention of the prior art workers and their efforts, the need exists for a method for on-site construction of an open-ended assembly line plant using shipping containers with continuous passthrough of supply materials to the plant, fabrication and removal of products from the assembly line.

[0011] Therefore, it is a general object of the present invention to provide a method for on-site assembling of a modular structure.

[0012] It is a further object of the present invention to provide a method of on-site assembly of a structure using multiple shipping containers transported to the site and joined together at the site to form a building structure such as a factory.

[0013] It is another object of this invention to provide a method of using shipping container modules containing assembly line equipment for the construction of an open-ended manufacturing plant with a continuous passthrough of supplies into the plant for fabrication and removal of product from the plant.

[0014] It is yet another object of the present invention to provide a method for constructing such assembly line plant adapted to be disassembled and transported in its entirety to another location.

[0015] It is an additional object of the present invention to provide a structure such as a plant or a factory of the type herein described.

[0016] It is yet an additional object of the present invention to provide a modular factory for the purpose of manufacturing products such as modular homes.

[0017] The foregoing and other objects and features of the present invention will become more apparent from the ensuing detailed description taken in conjunction with the accompanying drawings which form part of this application.

SUMMARY OF THE INVENTION

[0018] The present invention provides a method for constructing modular factory from standard shipping containers. The shipping containers which contain the equipment and parts in pre-assembled position are shipped to the site where they are linked together to define the walls of the factory which surround the factory equipment. A roof structure covers the shipping containers from one side wall to the other and one or more doors in the sides of the shipping container permits access to the interior of the factory. Supply containers can be mounted on a slab or other suitable surface adjacent the main storage containers, preferably in perpendicular relation, in order to assure the continuous supply of factory materials. An optional supply track moves the supply containers in order to deliver the supply materials inside the factory and also to transport products outside the factory. An optional foundation comprised of half height shipping containers raises the factory to a height of a conventional truck dock for tractor-trailers to dock to provide supplies.

[0019] The term shipping containers as used herein refers to the those containers used in combination to form the factory walls and they are also referred to as storage containers or main storage containers as they also have a storage function. The containers used to provide supplies to the factory may also be standard shipping containers but are referred to as supply containers to avoid confusion with those used to form the factory walls.

[0020] The main storage containers may also be stacked in rows, if desired, and stairways are installed for providing access from one level to the other. The supply containers can be moved on a supply track with turntables located at the ends of the assembly track and the supply tracks for moving the carriages or supply containers to the desired location(s).

[0021] The present invention also provides a portable modular factory which can be assembled on site and readily disassembled for transporting the factory to another site.

BRIEF DESCRIPTION OF THE DRAWINGS

[0022] In the drawings, wherein like reference numerals are employed to designate like parts wherever possible:

[0023]FIG. 1 is a perspective view of a novel factory constructed according to the present invention showing the shipping containers aligned in abutting position relative to each other to form the building walls, and further showing the supply containers used for delivery of the materials required for product fabrication;

[0024]FIG. 2 is a facade perspective view of the factory shown in FIG. 1;

[0025]FIG. 3 is a perspective elevational view of the interior of the factory;

[0026]FIG. 4 is a plan view of a single track version of the factory illustrated in FIGS. 1-3 showing three sets of shipping containers aligned in parallel to form the building wall;

[0027]FIG. 5 is similar to FIG. 4 with the addition of single perpendicular supply container;

[0028]FIG. 6 is similar to FIG. 5 except for using double perpendicular supply containers;

[0029]FIG. 7 is a view similar to FIG. 4 with shipping containers and a single assembly track and parallel abutting supply containers;

[0030]FIG. 8 is a view similar to FIG. 4 except for using additional shipping containers and increased assembly line track length;

[0031]FIG. 9 is a view similar to FIG. 8 with the addition of parallel supply containers and supply tracks for movement of these containers;

[0032]FIG. 10 is a view similar to FIG. 9 with the addition of turn tables located at the respective ends of each track;

[0033]FIG. 11 is a view similar to FIG. 10 with additional shipping containers and supply containers, and corresponding addition of assembly track, supply track and turn tables at the terminal ends of the track that represents a segment of an unlimited multiple assembly line plant;

[0034]FIG. 12 is a view similar to FIG. 6 with the addition of another assembly track, and turnout for parallel or switch-back assembly line(s);

[0035]FIG. 13 is a front elevational view of the factory shown in FIG. 2 with roll-down doors in closed position;

[0036]FIG. 14 is a side elevational view of the factory shown in FIG. 4 having three sets of storage units;

[0037]FIG. 15 is a longitudinal section taken along the line 15-15 of FIG. 12;

[0038]FIG. 16 is a partly perspective schematic view illustrating the method of loading and unloading supply containers on-off tractor trailers by means of automotive lifts;

[0039]FIG. 17 is a plan or aerial view showing one movement sequence of the supply containers (or carriages), their unloading and positioning using turntables in accordance with the method of this invention; and

[0040]FIG. 18 is similar to FIG. 13 having half-height containers as a foundation or base to elevate first level main storage units to standard truck dock height.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT OF THE INVENTION

[0041] In the ensuing description of the invention the term “building” is sometimes used to refer to a factory or a plant constructed by the method of the present invention. Also the terms “shipping containers” and “storage containers” refer to containers generally made of steel. These containers contain various factory components mounted therein at defined positions prior to their transportation to the building site.

[0042] Referring now to FIGS. 1-3, and in particular to FIG. 1, there is shown steel shipping containers 24 stacked and aligned relative to each other thus forming the major components of the building. The shipping containers 24 are bolted to the primary slab 44 by conventional means, and they abut one another with a gasket to form a weather tight seal. Two sets of steel shipping containers 24 are shown set on the slab 44 in order to define the length of the building. These shipping containers are modified prior to assembly at an offsite location by adding one or more sets of water tight doors 58 on the side walls of each container 24. Each door is welded to the structural frame of the container similar to the doors on the end walls of a standard container.

[0043] The shipping containers 24 are removably linked together to form the building walls, but not necessarily linked to the opposite structure. A roof structure 36 spans the top of the shipping containers, said roof being an inflatable membrane, although other roof structure may be installed such as, e.g., a truss system. Steel cables 70 are attached via clamps and turn buckles (not shown in the drawing) to the walls of the storage containers. The membrane roof can then be unfolded across the cables and inflated by a compressor. The membrane roof can be attached via pegs through the top storage container or via clamps and ties to the steel cables. The roof end walls (gables) 34 are assembled and installed in a similar manner. An exhaust fan 32 is installed in each roof end wall 34 via a bolted channel to the door header 54 (not shown). The end walls house one or more standard roll up garage doors 62. Column 48 (optional) is bolted at its base 50 to the slab 44 and is anchored thereto. The opening header 54 (not shown) is bolted to the column 48 and the main storage units 24 via brackets. Door tracks 64 are bolted to the main storage unit 24 and the column 48 on either side. The overhead door 68 is installed by directly bolting it to the header (not shown).

[0044] Also shown in FIGS. 1-3 are supply containers 22 for continuous supply of materials to the production floors of the building. The supply containers 22 are placed on the auxiliary slab 46 perpendicularly against the storage containers 24 at the door opening 58. A standard vinyl and foam-docking collar is placed around the door opening 58 to insure weather tight seal between the containers.

[0045] Assembly line production is facilitated by the parallel rails or tracks 26 which are installed on the slab 44 and are fastened thereto. As shown for example in FIG. 2, the tracks 26 run parallel to the end walls and carry a carriage 42 for use in assembling the modular building, and other products. The carriage 42 runs down one side of the building at various assembly stations and, if needed, a switch track 28 is installed to shift fabrication functions to another set of parallel tracks inside the factory or to operate two assembly lines simultaneously.

[0046] Referring to FIG. 3, moveable stairs 52 are installed to allow access to the upper main storage units when the shipping containers are in stacked position to form a building having more than one level. The steel cables 70 across the top of the walls 20 serve several purposes, from lateral ties to support for the lighting 72 and utilities. The lights may be suspended from the cables 70 with standard cable clamps. Pneumatic lines suspended from the cables feed different tools at each workstation. Lighting and utilities can also be supported by brackets in conventional manner. Brackets can be bolted to the walls of the main storage units. Roof supports such as trusses can also be utilized.

[0047] In FIG. 4, three sets of storage units 24 are removably linked and aligned in parallel position to define the walls of the building. Also shown is the roof structure outline 36 and the stair unit 52 in relation to the upper storage containers in order to permit access to these containers. A single assembly track 26 provides for movement of the carriages 42.

[0048] In FIG. 5, the perpendicular supply containers 22 are shown placed at the same elevation as the main storage containers 24 by conventional methods thus allowing a greater amount of material supply to the factory.

[0049] In order to allow for even greater or continuous supply of material to the factory, double perpendicular supply containers 22 are placed adjacent each storage wall 24. See FIG. 6. The provision of double supply containers allow an empty container to be removed and replaced while the second container continues to supply materials. Space savings on a restricted site may be realized by the addition of parallel abutting supply containers 22, as shown in FIG. 7. Addition of more storage containers as in FIG. 8 results in further growth to the building. With the addition of storage containers, the roof structure 36 must be extended along with the assembly track 26 and the number of stair units 52. If desired, and as shown in FIG. 9, parallel supply containers may be placed on the supply track 27. These supply containers are placed on wheeled assemblies or carriages by conventional methods, such as a crane or automotive lift 84 and can be moved as required for the assembly, or as needed for materials in the factory. If the factory is raised and used as a conventional truck dock as shown in FIG. 18 then supplies are provided by parking tractor trailers perpendicular to exterior walls of the factory.

[0050] In order to further improve movement of the supply containers, there is shown, in FIG. 10, the turn tables 78 located at the ends of the assembly track 26 and supply track 27 for movement of products and supplies. The use of turn tables 78 allows for supply container 22 or the products to be moved in any desired sequence.

[0051] In FIG. 11, the storage containers 24 are placed in alternating fashion relative to the assembly track 26 and supply track 27. In this arrangement, the roof 36 will cover the factory floor of each set of storage containers 24. As in the embodiment of FIG. 10, the turntables 78 are installed at the ends of the tracks, allowing for movement of the products or the supply containers 22. Thus, this method provides for unlimited growth of the factory in both lateral direction (as in FIG. 8), and the parallel direction. Factory height can be increased, if desired, by stacking additional main storage units 24 and supply containers 22.

[0052] Referring to FIG. 12, the invention illustrated therein is similar to that described in connection with FIG. 6, but for the addition of another assembly track 26. Thus, the storage containers 24 are placed further apart in order to accommodate additional track. Dual perpendicular supply containers 22 are used, however, if desired, single parallel or angled supply containers can be used. As in all storage wall containers, there are door openings in each side 56 in order to allow for flow of supply materials. Additional support column 48 is provided to support the overhead doors 68 (see FIG. 13) and the additional width of the factory. Switch tracks 28 permit switching from one track to another.

[0053] As previously discussed in relation to the building structure illustrated in FIGS. 1-3, and referring to FIG. 13, the parallel main storage units 24 are stacked and placed on primary slab 44 or other material or prefabricated deck and are secured thereto. If necessary, a secondary slab 46 is used to support the supply containers 22 shown perpendicular to the storage containers. At each end wall, an optional column 48 is placed to support the overhead door unit 68. The overhead door tracks 64 are fastened to the interior walls of the main storage units and the optional column 48 to allow proper functioning. Located above the door unit 68 is the roof end 34 housing the exhaust fan 32 to permit air circulation.

[0054] In FIG. 14, there is shown a side elevation of the structure shown in FIGS. 6 and 12 with three sets of abutting storage containers 24, and dual perpendicular supply containers 22 placed on the secondary slab 46, although a singular supply container may be used. The roof structure 36 caps the storage containers 24.

[0055]FIG. 15 illustrates the storage containers 24 placed in abutting and stacked positions on the primary slab 44 to form the wall of the factory. The stairs 52 provide access to the upper storage containers via the door openings 56 which may be enclosed by the storage unit door 58. The overhead door 68 and track 64 are fastened to the wall of the storage containers and the roof structure 36 caps the top of the storage container with individual inflatable cells 31 defining the roof membrane in this embodiment.

[0056] The transportation of the modular sections for on site assembly of the novel factory is shown in FIGS. 16 and 17. The shipping containers 22 are transported to the construction site using truck 82. The supply containers 22 are unloaded onto the carriage 42 using a pair of automotive lifts 84. The storage containers 24 are assembled by placing them on the primary slab 44 as described in connection with FIG. 1. Once the supply containers are placed on the carriage 42 they can be transported to any location by using a proper combination of the turntables 78. In order to remove the supply containers 22, the foregoing operation is reversed. The raised loading pad 88 allows the truck 82 to ride over the tracks 26,27.

[0057] Specifically, FIG. 16 illustrates the loading/unloading of supply containers 22. The placement sequence is partially shown in FIG. 17. Not shown is the unloading of product from carriage 42 and loading onto truck utilizing automotive lifts 84. The supply containers arrive at site by truck and are removed from trailer and placed onto carriage 42 (not shown) using a pair of automotive lifts 84, in this embodiment. Once a supply container is placed on carriage 42 (not shown), it can be transported to the desired location by using a combination of turntables 78 and the proper track segments. To remove empty supply containers 22, the foregoing operation is reversed. Product, such as modular house modules, follow the same sequence using the assembly line track 26. The raised loading pad 88 with ramp 90 allows truck 82 to properly ride over track 26.

[0058] As illustrated in FIG. 18, main storage units 24 are raised on half height containers 25 forming a conventional truck dock configuration for delivery of supplies. Tractor trailers (or trucks) back-up to the main storage units 24 which are at standard dock height, and the supply containers 22 remain on the trailer chassis. 

1. A portable modular factory comprising at least two shipping containers containing preassembled factory building components, said shipping containers being removably linked together to form a pair of opposed walls of said factory, a roof structure formed over said shipping containers, a passageway extending between said opposed walls of said factory, at least one access opening in each of said opposed shipping containers for transportation of supply materials to said passageway via said access opening.
 2. A portable modular factory as in claim 1 further including at least one supply container substantially adjacent at least one of said shipping containers.
 3. A portable modular factory as in claim 2 further including at least one assembly line track.
 4. A portable modular factory as in claim 3 further including at least one supply line track for moving the supply container.
 5. A portable modular factory as in claim 2 wherein a supply container is placed substantially perpendicular to each shipping container.
 6. A portable modular factory as in claim 2 wherein a supply container is placed substantially parallel to each shipping container.
 7. A portable modular factory as in claim 2 wherein at least two spaced apart supply containers are placed substantially perpendicular to a shipping container.
 8. A portable modular factory as in claim 2 wherein at least two spaced apart supply containers are placed substantially adjacent to at least one shipping container.
 9. A portable modular factory as in claim 4 wherein at least one supply container is placed substantially parallel to each shipping container in supply communication through said access opening to said passageway.
 10. A portable modular factory as in claim 4 further including a means at the respective ends of each of said tracks operatively associated therewith for causing movement of each track.
 11. A portable modular factory as in claim 10 wherein each of said means is a turntable.
 12. A portable modular factory as in claim 2 wherein at least two rows of at least one main storage unit stacked one above the other and wherein a stairway is provided for access from one row to the other.
 13. A portable modular factory as in claim 3 wherein at least two rows of at least one shipping container each are stacked one above the other and wherein a stairway is provided for access from one row to the other.
 14. A portable modular factory as in claim 4 wherein at least two rows of at least one shipping container stacked one above the other and wherein a stairway is provided for access from one row to the other.
 15. The method of constructing a portable modular factory from shipping containers containing factory components in said containers, said method comprising: (a) securing at least two shipping containers on a supporting foundation, linking said containers in substantially abutting relation to form walls of said factory, (b) installing a roof structure over the top of said containers, (c) installing an access opening in the side walls of at least one of said shipping containers, (d) installing an assembly track for moving product through said factory.
 16. A method as in claim 15 wherein each shipping container is located offsite and transporting each container to the factory site.
 17. A method as in claim 15 wherein means is used for moving said product through said factory.
 18. A method as in claim 16 wherein means is used for moving said product through said factory.
 19. A method as in claim 15 wherein at least two rows of shipping containers are stacked each over the other and a stairway is installed for access from a lower row to an upper row.
 20. A method as in claim 16 wherein at least two rows of shipping containers are stacked each over the other and a stairway is installed for access from a lower row to an upper row.
 21. A method as in claim 17 wherein at least two rows of shipping containers are stacked each over the other and a stairway is installed for access from a lower row to an upper row.
 22. A method of fabricating modular buildings through the use of a modular factory, comprising the steps of: (a) adapting shipping containers for combination into a modular factory, (b) further adapting said shipping containers to contain equipment for fabricating modular buildings, (c) transporting said shipping containers to a factory site, (d) combining said shipping containers to form a modular factory on said factory site, and (e) fabricating modular buildings at least in part in said modular factory.
 23. A method of fabricating modular buildings through the use of a modular factory in accordance with claim 22, additionally comprising the step of: further adapting said shipping containers for receiving supplies for fabricating modular buildings by means of external openings therein and for delivering said supplies by means of internal openings therein.
 24. A method of fabricating modular buildings through the use of a modular factory in accordance with claim 23, additionally comprising the step of: (a) adapting said external openings to receive supply container modules, (b) locating said internal openings opposite said external openings to permit straight line pass through of supplies from said supply container modules through said shipping containers to the factory floor of said modular factory.
 25. A method of fabricating modular buildings through the use of a modular factory in accordance with claim 23, additionally comprising the step of: (a) raising entire factory to conventional truck dock elevation, and (b) locating standard container and trailer to external openings to supply factory.
 26. A method as in claim 22 wherein at least two rows of shipping containers are stacked each over the other, and a stairway is installed for access from one row to the other row.
 27. A method as in claim 23 wherein at least two rows of shipping containers are stacked each over the other, and a stairway is installed for access from one row to the other row.
 28. A method as in claim 24 wherein at least two rows of shipping containers are stacked each over the other, and a stairway is installed for access from the lower level to the upper level.
 29. A modular building fabricated by the method of claim
 22. 30. A modular building fabricated by the method of claim
 23. 31. A modular building fabricated by the method of claim
 24. 32. A modular building fabricated by the method of claim
 25. 33. A system for fabricating products on a temporary site through the use of a portable factory, comprising the steps of: (a) selecting a site, (b) preparing said site to receive a portable factory, (c) assembling a plurality of first shipping containers to form a portable factory on said site, and (d) fabricating products by means of said portable factory.
 34. A system for fabricating products on a temporary site through the use of a portable factory in accordance with claim 33, additionally comprising the steps of: (a) docking supply shipping containers to at least one opening provided in an external wall of at least one of said first shipping containers of said portable factory, and (b) delivering supplies to said portable factory by means of said supply shipping containers.
 35. A system for fabricating products on a temporary site through the use of a portable factory in accordance with claim 33, additionally comprising the steps of: (a) disassembling said portable factory, and (b) removing at least one of said first shipping containers from said site.
 36. A building fabricated by the system of claim
 33. 37. A building fabricated by the system of claim
 34. 38. A building fabricated by the system of claim
 35. 39. A system as in claim 33 wherein said product is a building.
 40. A system as in claim 34 wherein said product is a building.
 41. A system as in claim 35 wherein said product is a building. 